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Procedia CIRP 32 ( 2015 ) 58 – 63

The 5th Conference on Learning Factories 2015 Green Factories Bavaria: A Network of Distributed Learning Factories for Energy Efficient Production

S. Kreitleina,*, A. Höftb, S. Schwenderc, J. Franked *

a,b,c,d Institute for Factory Automation and Production Systems Friedrich-Alexander-University of Erlangen-Nürnberg, Germany Fuerther Str. 246b, D-90429 Nuremberg

* Corresponding author. Tel.: +49-0911-5302-9069; fax: +49-0911-5302-9070. E-mail address: [email protected]

Abstract

The Green Factory Bavaria project contributes to the ability of Bavarian companies to improve their resource consumption. The main impulses include the knowledge transfer of applied research in the industry and the organization of experience exchange among companies. Therefore, Bavarian-wide so-called Green Factories for energy-efficient production are being developed and expanded, see, for instance, the learning and research platforms at the Technische Universität in Munich, the Friedrich-Alexander-University Erlangen-Nürnberg as well as at Universities of Applied Sciences in Amberg/Weiden, Ansbach, Coburg, Hof, Nuremberg, and Schweinfurt/Würzburg. Together, universities and companies are developing technical solutions and methodological approaches for the reduction of resource consumption and are presenting the latest Green Factories findings, where theoretical training can be made comprehensible through demonstration. The companies are supported through individual consulting services, while internet-based checklists and benchmarking analyzes help to determine the need for action. At each location specific Bavarian-wide coordinated technology priorities as well as cross-cutting issues are presented. Joint activities are processed, thereby ensuring the exchange of information among the institutions as well as with the industry. In the model factories for energy-efficient manufacturing innovative industrial partners shall receive the opportunity to demonstrate advanced techniques and technologies for energy-efficient production in the available laboratory and production areas, develop hand-in-hand with scientists from the participating research institutions, build a network among themselves, and circulate the findings effectively to users and students.

© 20152015 The Authors. PublishedPublished by by Elsevier Elsevier B.V. B.V. This is an open access article under the CC BY-NC-ND license (Peerhttp://creativecommons.org/licenses/by-nc-nd/4.0/-review under responsibility of the scientific committee). of the 5th Conference on Learning Factories 2015. Peer-review under responsibility of the organizing committee of 5th Conference on Learning Factories (CLF 2015) Keywords: Energy-efficient production, Interdisciplinary research-groups, Knowledge exchange

1. Introduction [11]. The rising costs of German energy prices could be stopped and the growing supply gap closed by means of Germany’s exit from nuclear power leaves the country with dramatic energy savings in all areas of energy consumption. two problems: 1. an ever-growing energy shortfall in general Hence, the issue of energy efficiency is becoming increasingly and 2. a shortage of electrical energy in lieu of the country’s important. Even though more than a quarter of the total expansion of electric mobility in particular. [9] As of yet, consumption of electricity in Germany is used in private renewable energies are unable to close this gap and to ensure households, with nearly 44.2% the industry is the main drive of security of supply. As current energy price developments electricity consumption. Thus, it can be assumed that the illustrate, the experienced shortage results in a steady increase successful implementation of investigations for increasing the of electricity prices [10]. In comparison with other European energy efficiency in the manufacturing sector is particularly countries electricity is particularly expensive in Germany. fruitful. This assumption can be confirmed by looking at the According to a report by the Federal Ministry of Economy and economic savings of electric energy: with about 50.3 TWh the Energy in the field of industrial users Germany presents itself industrial sector has the greatest potential in this comparison. as the fourth most expensive location, however, in respect to Therefore, the identification of potentials in order to increase current prices for households, it is second only to Denmark

2212-8271 © 2015 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the organizing committee of 5th Conference on Learning Factories (CLF 2015) doi: 10.1016/j.procir.2015.02.219 S. Kreitlein et al. / Procedia CIRP 32 ( 2015 ) 58 – 63 59 energy efficiency in the manufacturing sector is the focus of the transfer the existing knowledge. The integration of Green research project Green Factory Bavaria. Factories in the university education ensures the awareness of The phasing out of nuclear energy as decided by the German government (finished by 2022) results in the gradual shutdown of the four remaining Bavarian nuclear power plants. [1] The major part of electricity in Bavaria stems form nuclear power (57,6%). Combined with the planned expansion of electro mobility in Bavaria (200.000 cars by the year 2020) it is necessary to sustainably close the resulting gap in the supply of electrical energy on the technology and/or production side. [2] The already begun forceful expansion of renewable energy cannot be realized economically and in time; it will not be able to make up for the loss of nuclear power in and of itself. The high importance of protecting the natural foundations of life in Bavaria and the commitment to the most efficient use of energy (Bavarian Constitution Article 141, paragraph 1) requires the realization of sustainable, environment-friendly, and landscape compatible measures. [3] A particularly effective toehold is the consistent reduction of energy requirements of manufacturing companies. [4] Recent studies estimate a savings reservoir of up to 30%, whereby the electrical power of a nuclear power plant in Bavaria could be substituted. [5] However, there is often a lack of necessary knowledge on the factory level in Fig. 1: Green Factories of the universities and the Fraunhofer research groups order to realize these potentials. [12] At the same time, the in Bavaria. Bavarian companies and research institutes have access to a students and fosters their knowledge before they start their world-leading technology base for the development of careers. Through the processing of research priorities, new resource-saving production processes, automation, and control processes are developed further or newly invented and technologies. [13] The task is therefore to reduce energy and Bavaria’s ability for innovation is obtained while existing resource consumption of manufacturing companies sustainably methods and tools are extended; thus, Bavarian companies can in order to secure the workplaces of the economic and tourism benefit directly. region Bavaria. Manufacturing companies in Bavaria must be The Green Factories feature demonstration, learning, and supported through the identification of potential savings and research platforms while being an indispensable contribution the implementation of saving actions. for making problems and solutions in the field of energy 2. Goals of the Green Factories efficiency understandable and achievable for companies. The relevance of such platforms is reflected, for example, in the 2.1. Energy self-sufficient Green Factories in Bavaria Learning Factory for Energy Productivity (LEP, The model factories for energy-efficient production in www.energielernfabrik.de) in Munich, which was awarded by Bavaria pursue the long-term goal of being able to work the initiative “Germany - Land of Ideas” in 2012 under the completely energy self-sufficient. To reach this goal, methods patronage of the German President. The Green Factories and technologies for optimizing the energy consumption in the Bavaria project makes a significant contribution to reduce the manufacturing process and for reducing the heat losses in the energy demand in manufacturing companies and thus to reduce laboratory halls are developed. [14] Furthermore, strategies for the entire Bavarian energy demand sustainably. Hereby, the adapting the energy consumption to the energy offer as well as decoupling of economic growth and resource consumption, as methods for decentralized renewable energy generation are requested by the Bavarian government, is supported. [2] In developed and implemented in the Green Factories. addition, the reduction of energy requirements contributes to The primary objective of the Green Factory Bavaria project the goal of generating half of the electricity demand from is to enable the Bavarian industry to reduce energy renewable energy sources by 2021. consumption in the production. For this, saving potentials have 2.2. Interdisciplinary research of energy-saving production to be identified and the companies’ awareness in this regard has technologies to be raised. Therefore, Green Factories for energy-efficient production are built at universities in Munich, Erlangen, The Green Factories in Bavaria bundle research Nuremberg, Amberg/Weiden, Ansbach, Coburg, Hof and competencies of all relevant disciplines for energy efficient Schweinfurt/Würzburg and at the Fraunhofer Research Groups production, such as mechanical engineering, production in Augsburg and Bayreuth (see Fig. 1). engineering, electrical engineering, information technology, Their main task is the transfer of knowledge regarding process engineering as well as materials and economic science. energy and resource efficiency among companies. In particular, They consider all fundamental types of energy, such as the small and medium-sized enterprises (SMEs) are supported, as energy needed for moving, for light, for information they are the backbone of the Bavarian economy. Furthermore, processing, for production processes, for heating, cooling, and the Green Factories are educationally involved in order to air conditioning. [14] Moreover, they are dedicated to the 60 S. Kreitlein et al. / Procedia CIRP 32 ( 2015 ) 58 – 63

energy use in production, logistics, and administration [17] (see x Establishment of a Bavarian network "Energy-efficient Fig. 2). Production" for the exchange of effective measures for energy saving in manufacturing companies x Training events and implementation of a national congress on energy-efficient production x Technical presentations on the basis of specific demonstrators, which are produced on complementary production cells in the Green Factory x Implementation of consulting projects for the development of energy saving potentials in the production environment of interested companies x Development of educational games and IT-simulations x Increase of transparency of energy consumption by new measurement method x Internet presence with energy-potential-quick-check, checklists, methods etc. x Training of the students through internships, tutorials, Fig. 2: The Green Factories explore interdisciplinary energy-saving academic papers etc. production technologies in all areas of application. x Publications (journals and books) With a clear focus on energy efficiency in the production x Development of systematic (internet-based) checklists as and a state-wide, interdisciplinary collaboration the Green well as analysis and evaluation systems for rapid self- Factories Bavaria can be expanded into an internationally assessment of the status and the need for action as well as visible research network. the generation of the first emergency measures for manufacturing companies 2.3. Knowledge exchange between universities, production technology providers and manufacturing companies First and foremost, the Green Factories represent learning platforms. Industry representatives and students can learn In the Green Factories methods and systems for energy methods and tools to increase energy efficiency through efficient production are disclosed. They serve the economy as education and training actions. Currently, there rarely exist demonstration platforms for methodological and technical uniform procedures for the implementation of energy solutions for the energy-efficient design and improvement of efficiency projects in companies (especially in SMEs); existing and new production systems. [18] Additionally, the potentials thus remain undetected. Therefore, procedures (e.g. effects and interactions of measures are identified and the methodology of energy value stream [6], [7]) are presented improvements – not only on the local level – are achieved. In in the Green Factories that are nearing application. With the close cooperation with companies the Green Factories offer a combination of theoretical knowledge and practical unique opportunity to design energy efficient systems and/or components as well as the possibility of company employees verify methods for reducing the energy demands sustainably. to independently test, learn, and explore new things, the [15] With this, the economy’s swift and effective transfer is learning success rate can increase and skills can be expanded ensured. Through the model factories for energy-efficient [8]. Moreover, measurement procedures including the manufacturing, innovative industrial partners shall receive the associated measurement tools are shown: the studied methods opportunity to demonstrate advanced techniques and and tools can be applied directly in the companies while the technologies for an energy-efficient production in the available Green Factories offer support through consultations. laboratory and production areas, as well as to work jointly with As research platforms, it is important to anchor the Green scientists from the participating research institutions, network Factories in the research landscape. A trans-disciplinary among themselves, and make the findings available effectively orientation is necessary to achieve the best results within the to users and students. [16] With this unique approach to heterogeneity of the subjects. The close cooperation with collaborative research between industry and universities, in companies ensures the transfer of research results into addition to an efficient research in particular, a more effective industrial applications. Possible research areas are energy- and faster transfer of results to the economy is guaranteed. In minimized manufacturing processes, energy recovery, order to ensure proximity to the companies regionally interaction between buildings and production processes, distributed Green Factories are built. Institutions that deal with increasing transparency, and the integration of energy technical production issues in particular are suitable for this, as efficiency in the factory planning process. they have the necessary know-how. Each site focuses on clearly defined research themes of energy and resource efficiency; a 2.4. Clear vote of professional orientation coordinated cross-cutting as well as joint activities secure the Each of the Green Factory Bavaria locations represents and networking. In close cooperation between universities and researches specific topics that reflect the respective industrial companies advanced methods and technologies for competencies of the university and/or institute (see Fig. 3). energy-efficient production can be transferred for application. The following activities are scheduled: S. Kreitlein et al. / Procedia CIRP 32 ( 2015 ) 58 – 63 61

For an extensive handling of the diverse topics of energy- Based on the identified requirements, tailored transfer efficient production, innovative partners from the industry have solutions with wide acceptance in the industry can be to be involved with the Green Factories Bavaria. developed, all the while ensuring a high level of knowledge- flow within the company. In principle, various training types are used, see, for example, consulting and analysis performances in the production or education at the Green Factories. Another possible method is the attendance at workshops, in which the state of science and technology in the field of energy-efficiency in the production is explained. It is of the utmost importance to ensure a consistent coordination between all Green Factories at all times. The existing laboratory facilities and demonstrators of similar or other current issues in the industry located at the participating sites have been very well received in the past, which has resulted in a large transfer of research results for practical applications in companies. This very successful concept will be continued further in the Green Factories and is a central element in the utilization and transfer of technology. Fig. 3: Research priorities and cross-cutting issues of the Green Factories. [16] With the research assistants and students on the Green Factory sites, the project plan also has excellent potential for To accomplish this, each area of technology should be person-related transfer of expertise in the industry. By means represented only once to avoid internal competition. of writing theses in this research area, the students will be Cooperation with companies in the following technology and qualified for attractive jobs in Bavaria and elsewhere as well as application areas will be sought out especially: gain energy-efficient specific expertise, due to the project’s x Machine and plant construction wide applicability. x Process technology The individual Green Factories stand at the core of the x Communication, control, and information technology knowledge transfer. A specific structure regarding training x Electrical Drives aspects makes it possible to ensure the maximum energy x Pneumatic transparency, thus the effects of different measures can be x Hydraulic monitored and quantified; due to high costs this would not be x Heating and air conditioning possible in a real production environment. Moreover, the x Lighting technology mutability of resources provides further opportunities for x Energy generation testing various ideas and implementing measures. Part of the x Design offices training takes place at the individual demonstrators as they are x Financing of investments in energy-saving and energy built, for example in Augsburg, for the various themes of consulting operating organization or the joining and handling processes. In addition to site-specific topics inter-site cross-cutting and Here, interested companies can be trained on different levels of joint activities (e.g. participation in fairs, organization of detail on the topics of the individual Green Factories: from workshops and conferences) ensure a uniform alignment, raising awareness on energy-efficiency in the production to information sharing, and inter-regional transfer in enterprises. concrete technical and organizational solution proposals for an Within all this, a uniform representation, a common increase in efficiency of production. occurrence, and a structured marketing will be considered. The main results of the project are summarized in a guidance document that includes the action-guiding description of the 3. Design and implementation of a long-term transfer analytical steps for the identification, evaluation, and concept optimization of energy-efficiency in companies. Therefore, Improving energy-efficiency in the production is a key data collection forms for the targeted and expense-reduced challenge for Bavarian companies in the context of limited collection of the necessary input data as well as decision logics resources in the future. It is therefore important to ensure the are provided for evaluation. The achieved results are available transfer and utilization of the results by numerous measures. to the public by means of educational events. For this purpose, Established transfer activities such as the presence at fairs and already established training units at the research facilities – online as well as publications, events, seminars, and workshops which take place several times a year for industry executives – are thus being used. [15] provide ideal opportunities for incorporating the research The goal of the Green Factories Bavaria (the transfer of findings into adult education. knowledge within the industry) requires a comprehensive long- In addition to these training units, the Green Factories allow term concept. In another step (i.e. an intensive cooperation with for the exploration of new topics in the field of energy the Green Factories of the Fraunhofer research groups in efficiency in the production. The direct transfer of knowledge Bavaria), different ways of knowledge transfer are being to the industry is at the center of our considerations. In developed that ensure the best possible provision of energy- coordination and close cooperation with all Green Factories saving potentials and methods for increasing efficiency. already existing and newly acquired knowledge in this area will 62 S. Kreitlein et al. / Procedia CIRP 32 ( 2015 ) 58 – 63

be provided for interested companies and made available at x Energy Campus Nuremberg (EnCN) regular intervals during seminars or conferences. These x Energy Region Nuremberg e.V. meetings also provide an opportunity to adopt suggestions and x Bavarian Center for Applied Energy Research (ZAE experiences from the industry and incorporate them into the Bayern) Green Factories. x Learning Factory for energy-efficient production and the The project results will contribute to and established in IHK Fraunhofer Working Group on RMV iwb/TUM industry working groups on the topic of Green Factory Bavaria. x Bavarian Technology Center for Electric Power Working group meetings take place in enterprises of the Transmission (E | Drive Center) applicants, where project activities are presented and practical x Bavarian Technology Center for Resource Efficient and solutions developed together. Other topics of the working intelligent living (E | Home Center) groups are derived from specific contents of the four Green x Bavarian cluster power electronics; European Center for Factories or practical questions brought fort by a company. In Power Electronics e.V. (ECPE) addition to the studies and training units at the demonstrators x Institute of Power Electronic Systems (ELSYS) of the Green Factories, on-site services at the companies are 4.2. Network with the Energy Campus Nuremberg (EnCN) offered. The experts at Green Factories can then analyze product-specific questions and provide assistance and advice. The Energy Campus Nuremberg (EnCN) focuses on the Furthermore, requirements and conditions for the goal of sustainably powering the industry based on renewable implementation of issues in each Green Factory are obtained in energy sources. EnCN is a research platform for the this way. development and presentation of a closed renewable energy The homepage of Green Factory Bavaria is used as a chain. In particular, this includes the combination of electricity communication and information portal as well as a limited from renewable sources, energy storage, and smart feed as well access data exchange platform. This also includes the provision as by means of an efficient use and utilization. The close of guidance documents and data collection forms. cooperation between Green Factories and EnCN yields A comprehensive transfer of the project results is ensured extensive synergies from the power generation until its usage. through events and engagements of the participating research For this purpose, the existing regional industry and science institutions. The transfer of results to other industrial users is competencies will systematically be extended with the aim to provided by the activities of the research institutes, e.g. in the lead the chosen fields of energy research in Germany. The Automation Valley Northern Bavaria or in committees to research of EnCN focuses on the excellent know-how that is create standards and VDI. A joint training project for already available. The future goal is to develop new participants from the industry and academia concerning energy technologies, which are economically feasible and accepted management, the use of energy measurement technology, and among the people. performed optimization potentials for the compressed air 4.3. Collaboration with the Fraunhofer Institute consumption in industrial use has already been installed. Thus, a significant number of student project weeks have been The working group “resource-efficient processing machines conducted on site at industrial companies with the aim to detect (RMV)“ in Augsburg (part of the Fraunhofer Institute for saving potentials and develop questions and solutions. In Machine Tools and Forming Technology (IWU) Chemnitz) as general, an average saving potential of about 25% could be well as the working group “process innovation (PPI)” in detected. The detailed elaboration of these measures has Bayreuth (part of the Fraunhofer Institute for Manufacturing already been implemented in a variety of student theses, while Engineering and Automation (IPA) Stuttgart) have access to the findings of these activities also allocated for teaching the extensive knowledge base in the field of resource- purposes in the development of additional lecture units and new efficiency of the Fraunhofer Gesellschaft. The research can be internships at the various locations of the Green Factory built on an extensive study on energy-efficiency in the Bavaria. production by the Fraunhofer IWU [5]. The prioritized areas of these cooperation partners are the already installed learning 4. Bavaria-wide and trans regional networking factories concerned with energy efficient production 4.1. Integral integration of Green Factories in the Bavarian technologies and the efficiently compressed air supply. research landscape Additionally, training possibilities in the areas of production logistics, service engineering, energy efficiency of factory A state-wide and multidisciplinary approach for effective buildings, and additive manufacturing technologies – including processing of identified development areas is mandatory. The the installation of new vocational training institutions – are complex issues can be successfully resolved only through an offered . interdisciplinary collaboration between the disciplines of engineering, science, and economics. The Green Factories in 4.4. Cooperation between the Green Factories Bavaria cooperate with the relevant research institutions such In each quarter (during and after the project period) as universities and Fraunhofer Institutes. Some of the leading professional network meetings are performed to ensure the research institutions and organizations are listed as examples exchange of knowledge in order to synchronize and share the of the available excellent competencies: results of the local Green Factories in a timely and efficient x Cluster Mechatronics and Automation (CMA) manner. In addition, at least one exhibition in Bavaria per anno x Automation Valley Northern Bavaria (AVN) will be realized with a joint appearance to attract the interest of S. Kreitlein et al. / Procedia CIRP 32 ( 2015 ) 58 – 63 63 companies through the developed results from the Green involved in over 30 projects. They benefit significantly from Factories and promote its utilization. Already during the project the involvement and are providing plants and investments. period, a conference on the topic "resource-efficient production Therefore, the funding amount was doubled by the industrial technology" is organized to communicate scientific knowledge participation by at least 50%. more broadly. Acknowledgements 4.5. Bavaria-wide interdisciplinary researcher community The authors would like to express their sincere thanks to the (IZ) "Energy-efficient production" Freistaat Bayern for funding the project “Green Factory An interdisciplinary Bavarian-wide research community Bavaria” in the framework of the future initiative “Aufbruch will be established called "Energy-efficient production" for Bayern”. improved networking of distributed competencies. This 6. 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